Communication connectors having switchable electrical performance characteristics

• US 9,793,663 B2
• Filed: 02/02/2016
• Issued: 10/17/2017
• Est. Priority Date: 03/13/2013
• Status: Active Grant

• Current Assignee: Leviton Manufacturing Company Incorporated
• Original Assignee: Leviton Manufacturing Company Incorporated
• Inventors: Poulsen, Jeffrey Alan, Hammond, Gregory, Riley, Jon Clark, Marti, Franklin Conrad
• Primary Examiner(s): Riyami, Abdullah
• Assistant Examiner(s): NGUYEN, THANG H
• Application Number:
  US15/013,722
• Publication Number:
  US 20160149352A1
• Time in Patent Office: 623 Days
• Field of Search: 439188, 439344, 439941, 439676
• CPC Class Codes: H01R 13/659 with plural ports for distinct connectors
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: H01R 13/70 with built-in switch
• CPC Class Codes: H01R 13/71 Contact members of coupling parts operating as switch , e.g. linear or rotational movement required after mechanical engagement of coupling part to establish electrical connection
• CPC Class Codes: H01R 24/64 for high frequency, e.g. RJ 45
• CPC Class Codes: H01R 29/00 Coupling parts for selective co-operation with a counterpart in different ways to establish different circuits, e.g. for voltage selection, for series-parallel selection, programmable connectors

Abstract

A connector configured to operate in two different electrical performance modes. The connector may include a plurality of connector contacts, a plurality of contact pads, and an insulator having an insulating portion adjacent the plurality of contact pads. The insulator is movable between an insulating position and a non-insulating position. When the insulator is in the insulating position, the insulating portion insulates the plurality of contact pads from the plurality of connector contacts and the connector operates in a first one of the electrical performance modes. When the insulator is in the non-insulating position, the plurality of connector contacts contact the plurality of contact pads and the connector operates in a different second one of the electrical performance modes. The connector may be implemented as a plug or an outlet.

Claims

1. A communication plug for use with a cable, a first corresponding communication outlet, and a second corresponding communication outlet, the cable comprising a plurality of wires, the first corresponding communication outlet being configured to mate with the communication plug to form a first connection therewith, the second corresponding communication outlet being configured to mate with the communication plug to form a second connection therewith, the second corresponding communication outlet comprising at least one aperture, the communication plug comprising:

a substrate comprising a plurality of plated through-holes, a plurality of circuit paths, and a plurality of contact pads, each of the plurality of plated through-holes being configured to receive a corresponding one of the plurality of wires,

a plurality of plug contacts mounted on the substrate, a different one of the plurality of circuit paths connecting each of the plurality of plug contacts to a different one of the plurality of plated through-holes, the plurality of contact pads comprising a different contact pad corresponding to each of the plurality of plug contacts, at least a portion of the plurality of contact pads being connected to one or more coupling elements, each of the plurality of plug contacts being positioned to contact the contact pad corresponding to the plug contact; and

an insulator comprising an insulating portion and at least one projection, the insulating portion being adjacent the plurality of contact pads, the at least one projection being configured to transition the insulator from a first one of an insulating position and a non-insulating position to a different second one of the insulating position and the non-insulating position, the insulating portion of the insulator insulating the plurality of contact pads from the plurality of plug contacts when the insulator is in the insulating position, the plurality of plug contacts contacting the plurality of contact pads when the insulator is in the non-insulating position,

the first corresponding communication outlet pressing against the at least one projection when the first corresponding communication outlet is mated with the communication plug thereby causing the at least one projection to automatically transition the insulator, and

the at least one projection being received inside the at least one aperture of the second corresponding communication outlet when the second corresponding communication outlet is mated with the communication plug such that the second corresponding communication outlet avoids pressing against the at least one projection and avoids causing the at least one projection to transition the insulator.

2. The communication plug of claim 1, wherein the communication plug further comprises at least one biasing member exerting a biasing force on the insulator, the biasing force being sufficient to bias the insulator into the first one of the insulating position and the non-insulating position, and

the at least one projection is configured to receive sufficient force to overcome the biasing force and transition the insulator from the first one of the insulating position and the non-insulating position to the different second one of the insulating position and the non-insulating position.

3. The communication plug of claim 2, further comprising:

a housing comprising an exit aperture, the housing being configured to house the substrate, the plurality of plug contacts, and at least a portion of the insulator, the at least one projection extending outwardly from inside the housing through the exit aperture.

4. The communication plug of claim 3 for use with the first corresponding communication outlet comprising a sidewall defining a receptacle configured to receive a portion of the communication plug when the communication plug and the first corresponding communication outlet are mated, wherein the at least one projection is pressed against the sidewall of the first corresponding communication outlet when the portion of the communication plug is received inside the receptacle of the first corresponding communication outlet, the pressing exerting sufficient force on the at least one projection to overcome the biasing force and transition the insulator to the second different one of the insulating position and the non-insulating position.

5. The communication plug of claim 1, wherein the plurality of plug contacts and the plurality of circuit paths are configured to carry a plurality of differential signals at a data rate of up to about 40 Gigabits per second and an operating frequency of up to about 2 Gigahertz.

6. The communication plug of claim 1, wherein the plurality of plug contacts comprise a plurality of frame spades.

7. A communication plug for use with first and second communication outlets, the first communication outlet comprising a first receptacle with a plurality of first outlet contacts, the first communication outlet being configured to operate in accordance with a first standard, the second communication outlet comprising at least one aperture and a second receptacle with a plurality of second outlet contacts, the second communication outlet being configured to operate in accordance with a second standard, the first standard being different from the second standard, the plug comprising:

a housing having a portion configured to be received inside the first receptacle of the first communication outlet and form a first connection therewith, the housing being further configured to be received inside the second receptacle of the second communication outlet and form a second connection therewith;

a coupling element subassembly configured to provide electrical coupling in accordance with the first standard;

a plurality of plug contacts positioned inside the housing, the plurality of plug contacts being contactable through apertures in the housing by the plurality of first outlet contacts when the plug is received inside the first receptacle of the first communication outlet, and by the plurality of sec outlet contacts when the plug is received inside the second receptacle of the second communication outlet; and

a switch assembly having at least one projecting portion, the first communication outlet pressing on the at least one projecting portion and causing the switch assembly to move allowing the plurality of plug contacts to contact the coupling element subassembly when the plug is inserted into the first receptacle of the first communication outlet, the at least one aperture of the second communication outlet receiving the at least one projecting portion and avoiding pressing on the switch assembly thereby allowing the plurality of plug contacts to remain disconnected from the coupling element subassembly when the plug is inserted into the second receptacle of the second communication outlet.

8. The plug of claim 7, wherein the plurality of plug contacts comprise a plurality of frame spades.

9. The plug of claim 7, wherein the switch assembly slides in a first direction when the first communication outlet presses on the at least one projecting portion,

the switch assembly comprises a biasing member that biases the switch assembly in a second direction, and

the first direction is opposite the second direction.

10. The plug of claim 7, wherein the plug is a registered jack 45 type plug, and the first standard is Category 1, Category 2, Category 3, Category 4, Category 5, Category 5e, Category 6, or Category 6A.

11. A communication plug for use with first and second communication outlets, the first communication outlet comprising a first receptacle, the second communication outlet comprising at least one aperture and a second receptacle, the plug comprising:

an insulator comprising an insulating portion and at least one projection;

a first electrical circuit portion comprising a plurality of plug contacts; and

a second electrical circuit portion, the at least one projection being received inside the at least one aperture and the insulating portion being positioned in between the plurality of plug contacts and the second electrical circuit portion when the plug is inserted into the second receptacle of the second communication outlet, the insulating portion disconnecting the first electrical circuit portion from the second electrical circuit portion when positioned in between the plurality of plug contacts and the second electrical circuit portion, the first communication outlet pressing on the at least one projection and removing the insulating portion from in between the plurality of plug contacts and the second electrical circuit portion such that the second electrical circuit portion is connected to the first electrical circuit portion when the plug is inserted into the first receptacle of the first communication outlet, the plug operating in a first electrical performance mode when the second electrical circuit portion is disconnected from the first electrical circuit portion, and the plug operating in a different second electrical performance mode when the second electrical circuit portion is connected to the first electrical circuit portion.

12. The plug of claim 11, wherein the insulator slides in a first direction when the first communication outlet presses on the at least one projection, and

the plug comprises a biasing member that biases the insulator in a second direction, the first direction being opposite the second direction.

13. The plug of claim 11, wherein the second electrical circuit portion comprises electrical coupling elements that configure the plug to operate in the second electrical performance mode when the second electrical circuit portion is connected to the first electrical circuit portion.

14. A plug configured to mate one at a time with first and second outlets, the first outlet comprising a first receptacle, the second outlet comprising a second receptacle and at least one aperture, the plug comprising:

a plurality of electrical circuits;

a plurality of coupling elements that when connected to the plurality of electrical circuits electrically couple two or more of the plurality of electrical circuits together at least one of capacitively, inductively, or conductively such that the plug operates in a first electrical performance mode; and

a switching mechanism having at least one projecting portion and an insulating portion, the at least one projecting portion being received inside the at least one aperture and the insulating portion being positioned to disconnect the plurality of electrical circuits from the plurality of coupling elements when the plug is inserted into the second receptacle of the second outlet, the first outlet pressing on the at least one projecting portion and moving the insulating portion such that the plurality of electrical circuits are connected with the plurality of coupling elements when the plug is inserted into the first receptacle of the first outlet, the plug operating in a different second electrical performance mode when the plurality of coupling elements are disconnected from the plurality of electrical circuits.

15. The plug of claim 14, wherein the plug and the first outlet exhibit a first mated electrical performance in accordance with a first specification when mated together, and

the plug and the second outlet exhibit a different second mated electrical performance in accordance with a different second specification other than the first specification when mated together.

16. The plug of claim 15, wherein the first specification is Category 1, Category 2, Category 3, Category 4, Category 5, Category 5e, Category 6, or Category 6A.

17. A plug for use with a first outlet configured to operate in a first electrical performance mode and a second outlet configured to operate in a different second electrical performance mode, the first outlet comprising a first receptacle, the second outlet comprising at least one aperture and a second receptacle, the plug comprising:

a plurality of electrical circuits;

a plurality of coupling elements that when connected to the plurality of electrical circuits electrically couple two or more of the plurality of electrical circuits together at least one of capacitively, inductively, or conductively such that the plug operates in the first electrical performance mode; and

a switching mechanism having at least one projecting portion and an insulating portion, the first outlet pressing on the at least one projecting portion and moving the insulating portion into a first position where the plurality of coupling elements are connected to the plurality of electrical circuits when the plug is inserted into the first receptacle of the first outlet, the at least one projecting portion being received inside the at least one aperture and the insulating portion being positioned to disconnect the plurality of coupling elements from the plurality of electrical circuits when the plug is inserted into the second receptacle of the second outlet, the plug operating in the second electrical performance mode when the plurality of coupling elements are disconnected from the plurality of electrical circuits.

18. The plug of claim 17, wherein the plug and the first outlet exhibit a first mated electrical performance in accordance with a first specification when the plug is inserted into the first receptacle of the first outlet and the plug is operating in the first electrical performance mode.

19. The plug of claim 18, wherein the plug and the second outlet exhibit a different second mated electrical performance in accordance with a different second specification when the plug is inserted into the second receptacle of the second outlet and the plug is operating in the second electrical performance mode.

20. The plug of claim 19, wherein the first specification is Category 1, Category 2, Category 3, Category 4, Category 5, Category 5e, Category 6, or Category 6A.

21. A communication plug for use with a cable comprising a plurality of wires, the communication plug comprising:

a substrate comprising a plurality of plated through-holes, a plurality of circuit paths, and a plurality of contact pads, each of the plurality of plated through-holes being configured to receive a corresponding one of the plurality of wires,

a plurality of plug contacts mounted on the substrate, a different one of the plurality of circuit paths connecting each of the plurality of plug contacts to a different one of the plurality of plated through-holes, the plurality of contact pads comprising a different contact pad corresponding to each of the plurality of plug contacts, at least a portion of the plurality of contact pads being connected to one or more coupling elements, each of the plurality of plug contacts being positioned to contact the contact pad corresponding to the plug contact;

an insulator comprising an insulating portion and at least one projection, the insulating portion being adjacent the plurality of contact pads, the insulator being movable between an insulating position and a non-insulating position, the insulating portion of the insulator insulating the plurality of contact pads from the plurality of plug contacts when the insulator is in the insulating position, the plurality of plug contacts contacting the plurality of contact pads when the insulator is in the non-insulating position; and

at least one biasing member exerting a biasing force on the insulator, the biasing force being sufficient to bias the insulator into a first one of the insulating position and the non-insulating position, the at least one projection being configured to receive sufficient force to overcome the biasing force and move the insulator from the first one of the insulating position and the non-insulating position to a second different one of the insulating position and the non-insulating position.

22. The communication plug of claim 21 for use with a first corresponding communication outlet configured to mate with the communication plug to form a connection therewith, wherein the at least one projection is configured to automatically transition the insulator when the first corresponding communication outlet is mated with the communication plug.

23. The communication plug of claim 21, further comprising:

a housing comprising first and second exit apertures, the housing being configured to house the substrate, the plurality of plug contacts, and at least a portion of the insulator, the at least one projection comprising first and second projections that extend outwardly from inside the housing through the first and second exit apertures.

24. The communication plug of claim 23 for use with a corresponding communication outlet configured to mate with the communication plug to form a connection therewith, the corresponding communication outlet comprising a sidewall defining a receptacle configured to receive a portion of the communication plug when the communication plug and the corresponding communication outlet are mated, wherein the first and second projections are pressed against the sidewall of the corresponding communication outlet when the portion of the communication plug is received inside the receptacle of the corresponding communication outlet, the pressing exerting sufficient force on the first and second projections to overcome the biasing force and move the insulator to the second different one of the insulating position and the non-insulating position.

25. The communication plug of claim 21, further comprising:

a housing comprising an exit aperture, the housing being configured to house the substrate, the plurality of plug contacts, and at least a portion of the insulator, the at least one projection extending outwardly from inside the housing through the exit aperture.

26. The communication plug of claim 25 for use with a corresponding communication outlet configured to mate with the communication plug to form a connection therewith, the corresponding communication outlet comprising a sidewall defining a receptacle configured to receive a portion of the communication plug when the communication plug and the corresponding communication outlet are mated, wherein the at least one projection is pressed against the sidewall of the corresponding communication outlet when the portion of the communication plug is received inside the receptacle of the corresponding communication outlet, the pressing exerting sufficient force on the at least one projection to overcome the biasing force and move the insulator to the second different one of the insulating position and the non-insulating position.

27. The communication plug of claim 21, wherein the plurality of plug contacts and the plurality of circuit paths are configured to carry a plurality of differential signals at a data rate of up to about 40 Gigabits per second and an operating frequency of up to about 2 Gigahertz.

28. The communication plug of claim 21, wherein the plurality of plug contacts comprise a plurality of frame spades.